1

ZSE MAXX SERIESCo-rotating twin screw extruders

2 3Leistritz Extrusion Technology

ZSE MAXX TWIN SCREW EXTRUDER

↗ Overview

Leistritz is one of the worldwide leading manufacturers of twin screw extruders. It is only possible to off er a fully de-veloped product range by means of constant innovations and an open ear for the requirements of the users.

The ZSE MAXX series is a extruder series that off ers an ideal combination of high torque and large volume in ONE machine.

This opens up a great degree of freedom for users: increased throughputs and a signi� cant expansion of the process window are arguments that have convinced experts. This product range opens up the world of "Increased productivity through � exibility". For produc-tion, this means more effi ciency, thus ensuring a sustain-able future.

SIGNIFICANTLY MORE THROUGHPUT THANKS TO:

↗ maXXvolume high, free volume in the screw (OD/ID = 1.66)

↗ maXXsha� very high total torque due to patented splined sha� connection

↗ maXXcooling increased cooling capacity by means of optimized � ow of the liquid coolant through the barrel

↗ maXXtorque very high available speci� c torque (up to 15.0 Nm/cm³)

↗ Overview

» While previously, a choice needed to be made between a high- volume or high-torque machine, now virtually every application can be run on a ZSE MAXX twin screw extruder. «

control concept: individual integration of all conventional upstream and downstream equipment in one visualization and operat-ing panel

drive unit: extremely reliable and powerful co-rotating extruder gearbox

oil system for gearbox lubrication

high OD/ID (1.66) and high speci� c torque (15 Nm/cm³)

machine concept: platform design allowsa wide range of modules

cooling: barrel cooling concept with maintenance-free high-end valves

water-cooled AC drive

Convincing bene� ts

Example of a ZSE MAXX extruder

Example of a customized system

4 5Leistritz Extrusion Technology

When running volume-restricted processes such as dry-blends, pigment preparations, � llers or additive concen-trates, the increased volume of the ZSE MAXX extruders can be fully used. With an OD/ID of 1.66, Leistritz has found the optimum ratio between high volume and ef-fective energy input into the product. The shear eff ect in

maXXvolume

↗ ZSE MAXX features

More throughput by means of increased volume

the ZSE MAXX machine is slightly smaller compared to predecessor models, nevertheless, it facilitates excellent dispersion. At the same time, higher throughputs with an identical or even better quality can be achieved for many formulations.

maXXcoolingMore cooling capacity for a larger process window

↗ ZSE MAXX features

A

Center line distance

OD ID

» With lower cut screw � ights and larger external diameters, an increase in volume and thus improved throughputs of up to 30% are possible. «

ZSE MAXX twin screw extruders allow an increased throughput of up to 50 % compared to predecessor mod-els. This means that the energy balance in the processing unit changes and calls for an increased cooling capacity in some cases. This is why Leistritz has doubled the inlets and outlets for each barrel and developed a sophisticated cooling bore system to allow much more liquid coolant to � ow through the barrel, which facilitates increased cool-ing capacity.

The cooling capacity is fully utilized on account of the short distance between the cooling bores and processing chamber as well as the counter� ow principle. The pro-cessing unit is held by a functional carrier system with integrated cooling pipe installation. The high-quality coax valves are assembled in the frame in a very space-saving way.

WHY COAX VALVES?

↗ long service life

↗ short closing times

↗ compact design

↗ maintenance-free

↗ backward pressure-safe

↗ work from 0 bar upwards

FM

Ft

Fr

�

�

Ft

� = 0

DIN 5480 maXXsha� � = 30°Ft = cos � . FM

Fr = sin � . FM

� = 0°Ft = FM

Fr = 0

6 7Leistritz Extrusion Technology

maXXtorque

↗ ZSE MAXX features

More output for higher operating safety

Great demands are made on the gearbox of a twin screw extruder. With the relatively close axial distance of the two extruder screws, it has to transmit very high torque and counteract high backward pressure forces.

Leistritz thus uses an extremely powerful drive concept for its twin screw extruders. The transmission gear with

dual power distribution is a masterpiece of German engineering. The extremely high power densities were achieved by high-quality workmanship, constant re-search and long-standing know-how. It satis� es the very demanding requirements and convinces by a maximum torque density.

maXXsha� More splines for a better torque transmission

↗ ZSE MAXX features

THE GEARBOX ADVANTAGES AT A GLANCE:

↗ thick-walled housing

↗ highest degree of effi ciency

↗ noise-optimized by means of specially � nished gears

↗ continuous lubrication to avoid churning losses

↗ optimized service life through the use of high-performance oils

↗ for certain extruder sizes: the torque can be measured on drive sha� s

high-torque gearbox

safety clutch off ers protection for the gear-box against the very high � ywheel masses of the drive motor.

For a long time, the standard involuted spline connection according to DIN 5480 was the � rst choice for screw ele-ments and sha� s. However, when transmitting extremely high torques, the DIN 5480 spline pro� le comes up against its physical limits for thin-walled hubs. For this reason it was necessary to reconsider the spline pro� le

in order to further develop co-rotating twin screw ex-truders. The result - maXXsha� - is both amazing and simple: Since the power only has to be transmitted in one direction with a co-rotating twin screw, the spline pro� le is changed to an asymmetric shape.

A radial tension (Fr) is generated when transmit-ting torque, which puts additional stress on the screw element. This means that the screw � ights cannot be cut too low as the screw element would otherwise burst.

Hub

Sha�

Hub

Sha�

No additional radial tension (Fr) arises, i.e. the screw � ights can be cut lower and - bene� ting from the optimized shape stability - torque can be further increased.

ADVANTAGES OF THE ASYMMETRIC SPLINE SHAPE:

↗ The arrangement of several splines with the same root width → allows very high torque to be transmitted.↗ Errors can be reduced by a set direction of assembly.

energy-effi cient, water-cooled three-phase AC motor

M M

8 9Leistritz Extrusion Technology

↗ Effi ciency

The extrusion process is energy-intensive. In order to reduce energy costs, operators aim for both high throughputs and an optimum energy utilization. Leistritz can off er a number of solutions in this � eld.

↗ Effi ciency

Optimum OD/ID

An optimum screw diameter ratio plays an important role in the energy feed. The ZSE MAXX twin screw extruders with their high OD/ID achieve better mixing properties with a lower energy input. In a residence time study, a ZSE MAXX ma-chine (OD/ID = 1.66) and a predecessor model (OD/ID = 1.5) were compared with the same and a slightly modi� ed screw geometry.

Energy-effi cient drives

The energy � ows in a twin screw extruder cannot be trans-ported 100% into the product. The majority of the energy is mainly introduced into the melt via the drive and thus via

Insulating the processing unit

However, it is not only drive energy that is required to provide the energy needed for melting at low speeds. Energy also enters the process through the barrel heating. Leistritz off ers insulations for process-ing units to reduce the heat-up times and to use the barrel heating even more effi ciently.

1.8

1.6

1.4

1.2

1.0

0.8

0.6

0.4

0.2

0.0

the screws. Leistritz uses energy-effi cient, water-cooled high-torque drives as a standard solution here.

0 20 40 60t/s

E (t

)/s-

1

1.5 0.276

1.66 = 1.5 0.253

1.66 (mod*) 0.275

OD/ID SEI [kWh/kg]

RESIDENCE TIME DISTRIBUTION FUNCTIONS E(t)

* modi� ed screw geometry through the use of additional kneading blocks

OPTIMUM ENERGY UTILIZATIONNew "solutions"

loss through the gearbox and frequency converter

Pdrive = drive energy

Hin = energy input

Qcool = cooling energy

Qheat = heat energy

Hevap = evaporation

Hout = productenthalpy

Energy � ows in a twin screw extruder

10 11Leistritz Extrusion Technology

MODULAR SCREW SYSTEM

↗ Processing unit ↗ Processing unit

» The design of the correct screw geometry is the alpha and omega for a stable process. Our process engineers are experts in this � eld. «

Leistritz off ers a wide choice of screw geometries that can be combined in a large number of variations. Generally, there are conveying, kneading and mixing elements. The competence of the Leistritz process engineers enables

them to create an optimum screw design for the respec-tive application. Depending on the geometry, various screw elements are placed and � xed on the screw sha� which has a spline pro� le.

The heart of the extruder

KB (kneading block)↗ standard element in 30°, 45°, 60° and 90° design for melting, dispersing and incorporating � llers↗ The most important parameter is the off set angle between the kneading block disks and kneading block thickness (determines the energy input and melting capacity).↗ improved kneading eff ect thanks to re-conveying KB elements

GFF (co-rotating conveying element, non-self-wiping)↗ typically with a big pitch (has the largest free volume of all screw elements)↗ primarily used in the feeding zone↗ used for conveying solids (materials with a low bulk density can be added in higher quantities) ↗ hardly any energy input

GFA (co-rotating conveying element, intermeshing)↗ self-cleaning element with the Erdmenger pro� le↗ used for conveying, degassing and building up pressure↗ various pitches depending on the intended use and material to be processed

GFM (co-rotating conveying element, mixing)↗ grooved screw element↗ main job: distributive mixing↗ typical use: incorporation of glass � bers and liquids into the polymer matrix, wetting of pigments↗ improved mixing eff ect thanks to re-conveying GFM elements↗ low energy input

Example of a screw sha�

Material Material Thickness Hardness Protection against Remarkscode (mm) (HRC) Abrasion Corrosion

VSA100 Nitrided steel 0.4 >750HV on requestVSA200 Hot work steel through hardened 59±1 standardVSA300 Stainless steel through hardened 57-2 on requestVSA401 CrV-HIP material through hardened 64±1 on requestVSA402 CrNbV-HIP material through hardened 61±1 standardVSA503 Hastelloy/Stellite 3 45+5 on requestVSA504 WC material through hardened 1,450HV on request

OVERVIEW OF MATERIALS FOR SCREW ELEMENTS:

very high none very high

12 13Leistritz Extrusion Technology

↗ Processing unit ↗ Processing unit

MODULAR BARREL SYSTEM

barrel for LSB (Leistritz side feeder)

BARREL HEATING/COOLING

Heating cartridges are used to heat up the barrel in the fastest and most eff ective way. They enable:

↗ short heat-up times

↗ quick melting and wetting ↗ energy savings→ heating inside the barrel in contrast to heating bands or angular heaters (see � gure below) ↗ more effi cient spare part administration→ same type of heating cartridges for all barrel types

The optimum combination of cooling and heating is one of an extruder‘s essential quality characteristics. It plays a very important role so that every process can be adequately run. Each barrel hereby has a separate heating/cooling zone that can be heated or cooled as required.

Example: barrel with liner

feed barrel with opening to feed the material

The processing unit must naturally also have a modular structure in accordance with the screw geometry. Leistritz off ers barrels with various openings and in-serts for material feeding, degassing and venting for the

optimum interaction with the extruder screws. Depend-ing on the size of the machine, these are either � anged together or connected with tie rods.

Extensive portfolio

heating cartridges

cooling bores

bore for temp- erature sensor

Material Material Thickness Hardness Protection against Commentcode (mm) (HRC) Abrasion Corrosion

VSA100 Nitrided steel 0.4 >750HV on requestVSA200 Hot work steel through hardened 58+2 standard linerVSA300 Stainless steel liner through hardened 57-2 on requestVSA402 CrNbV-HIP liner through hardened 60±2 standardVSA403 NiCrB-HIP liner 3 60±2 on requestVSA404 WCNiCrB-HIP liner 3 63±2 on requestVSA501 NiCrB cast liner through hardened 60±2 on requestVSA502 Conforma Clad 3 63±2 on requestVSA504 WC liner through hardened 1450HV on request

very high none very high

OVERVIEW OF MATERIALS FOR BARREL ELEMENTS:

barrel to inject liquids

degassing barrel for degassing dome

closed barrel

14 15Leistritz Extrusion Technology

ZSE MAXX SERIES

↗ Series

System for maXXimum possibilities

↗ Series

The very high speci� c torque (up to 15 Nm/cm³) and the large volume (OD/ID = 1.66) in ONE extruder – this is what has distinguished the ZSE MAXX twin screw extruder in the mar-ket for over a decade. This enormous adaptability of the ZSE MAXX series provides the user with a processing advantage: A large range of processes can be covered with one ZSE MAXX twin screw extruder.

TypeScrew

diameter OD (mm)

OD/IDSpec. torque

density (Nm/cm³) up to max.

18 18.5 1.66 11.0

27 28.3 1.66 12.5

35 35.1 1.66 15.0

40 41.4 1.66 15.0

50 51.0 1.66 15.0

60 61.6 1.66 15.0

75 77.0 1.66 15.0

87 89.4 1.66 15.0

110 113.1 1.66 15.0

135 138.7 1.66 15.0

160 159.9 1.66 15.0

180 178.8 1.66 15.0

260 258.0 1.66 15.0

» The ZSE MAXX series is the most elaborate twin screw extruder series with a consistent OD/ID and high torque, which facilitates a scale-up from smaller machines to larger production plants. «

www.leistritz.com

↗ Leistritz Extrusionstechnik GmbH | Markgrafenstraße 36-39 | 90459 Nuremberg | Germany Tel.: +49 911 43 06 - 0 | extruder@leistritz.com

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EXTRUSION TECHNOLOGYAvailable for you all over the world

USA

Leistritz Advanced Technologies Corp., Somerville, NJ

FRANCE

Leistritz France Extrusion, Ceyzeriat

GERMANY

HeadquartersLeistritz Extrusionstechnik GmbH, Nuremberg

ITALY

Leistritz Italia Estrusione, Castellanza

SINGAPORE

Leistritz SEA Pte Ltd, Singapore

CHINA

Leistritz Machinery (Taicang) Co., Ltd., Taicang